Aerosol supply device

Abstract

To provide: an aerosol provision device; an aerosol provision system comprising the device and an article comprising aerosolizable material; and a method of heating aerosolizable material.SOLUTION: An aerosol provision device has: a heating zone 110 for receiving an article 10 including aerosolizable material 11; an outlet 120 through which aerosol is deliverable from the heating zone to a user in use; and a heating apparatus 130 for causing heating of the article when the article is located within the heating zone to thereby generate the aerosol. The heating apparatus is configured to, during a heating session, cause heating of a first portion 11a of the aerosolizable material to a temperature sufficient to aerosolize a component of the first portion, and heating of a second portion 11b of the aerosolizable material to a temperature sufficient to aerosolize a component of the second portion. The heating apparatus is configured to cause the heating of the first portion before or more quickly than the heating of the second portion.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an aerosol delivery device, an aerosol delivery system comprising an aerosol delivery device and an article containing an aerosolizable material, and a method for heating an aerosolizable material.The aerosol delivery device may be, for example, a tobacco heating product. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products are so-called "non-combustion heating" products or tobacco heating devices or products that release compounds by heating but not burning a material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] A first aspect of the present invention provides an article comprising a heating zone for receiving at least a portion of an article comprising an aerosolizable material, an outlet through which an aerosol can be delivered from the heating zone to a user during use, and a heating device for heating the article when the article is at least partially located within the heating zone, thereby generating the aerosol, wherein the heating device is configured to heat a first portion of the aerosolizable material located at a first position within the heating zone when the article is at least partially located within the heating zone during a heating session without combusting the first portion of the aerosolizable material. The heating device is configured to cause heating of the first portion of the aerosolizable material to a temperature sufficient to aerosolize the components of the first portion, and heating of a second portion of the aerosolizable material located at a second position within the heating zone when the article is at least partially located within the heating zone to a temperature sufficient to aerosolize the components of the second portion of the aerosolizable material without combusting the second portion of the aerosolizable material, wherein the heating device is configured to cause the heating of the first portion of the aerosolizable material before or more rapidly than the heating of the second portion of the aerosolizable material.

[0004] In an exemplary embodiment, the heating device comprises a first heating unit operable to cause heating of a first portion of the aerosolizable material, a second heating unit operable to cause heating of a second portion of the aerosolizable material, and a controller configured to operate the first and second heating units to heat the first portion of the aerosolizable material before or more quickly than heating the second portion of the aerosolizable material during a heating session.

[0005] In an exemplary embodiment, the controller is configured to discontinue supplying power to the first heating unit during at least a portion of the time period during which the controller is configured to operate the second heating unit.

[0006] A second aspect of the present invention provides an article comprising a heating zone for receiving at least a portion of an article comprising an aerosolizable material, an outlet through which an aerosol can be delivered from the heating zone to a user during use, and a heating device for heating the article when the article is at least partially located within the heating zone, thereby generating the aerosol, the heating device comprising: a first heating unit operable to heat a first portion of the aerosolizable material located at a first position within the heating zone when the article is at least partially located within the heating zone to a temperature sufficient to aerosolize components of the first portion of the aerosolizable material without burning the first portion of the aerosolizable material; and a second heating unit operable to heat a first portion of the aerosolizable material located at a second position within the heating zone when the article is at least partially located within the heating zone, the first heating unit operable to heat a first portion of the aerosolizable material located at a first position within the heating zone when the article is at least partially located within the heating zone to a temperature sufficient to aerosolize components of the first portion of the aerosolizable material without burning the first portion of the aerosolizable material. a second heating unit operable to heat a second portion of the aerosolizable material to a temperature sufficient to aerosolize components of the second portion of the aerosolizable material without combusting the second portion of the aerosolizable material, the second location being fluidly located between the first location and the outlet; a third heating unit operable to heat a third portion of the aerosolizable material located at a third location within the heating zone when the article is at least partially located within the heating zone to a temperature sufficient to aerosolize components of the third portion of the aerosolizable material without combusting the third portion of the aerosolizable material, the third location being fluidly located between the second location and the outlet; and a controller configured to operate the first, second, and third heating units.

[0007] In an exemplary embodiment, the controller is configured to operate the heating units independently of each other.

[0008] In an exemplary embodiment, the third heating unit is located between the second heating unit and the outlet.

[0009] In an exemplary embodiment, the second heating unit is located between the first heating unit and the outlet.

[0010] In an exemplary embodiment, the heating apparatus includes at least one further heating unit operable to heat further respective portions of the aerosolizable material located at further respective positions within the heating zone when the article is at least partially located within the heating zone to a temperature sufficient to aerosolize components of the further respective portions of the aerosolizable material without burning the further respective portions of the aerosolizable material.

[0011] In an exemplary embodiment, the heating units include respective resistive heating units.

[0012] In an exemplary embodiment, the heating units include respective induction heating units configured to generate respective varying magnetic fields.

[0013] In an exemplary embodiment, each of the induction heating units includes an inductor having a respective conductive element, each of the conductive elements including a conductive non-helical first portion coincident with a first plane, a conductive non-helical second portion coincident with a second plane spaced apart from the first plane, and a conductive connector electrically connecting the first portion to the second portion.

[0014] In an exemplary embodiment, the second plane is parallel to the first plane.

[0015] In an exemplary embodiment, the first portion is a first partial annulus, such as a first arc, and the second portion is a second partial annulus, such as a second arc.

[0016] In an exemplary embodiment, each of the conductive elements of a respective inductor at least partially surrounds a heating zone.

[0017] In an exemplary embodiment, the aerosol delivery device comprises a susceptor configured to be heatable by penetration of a fluctuating magnetic field, thereby causing heating of the heating zone.

[0018] In an exemplary embodiment, the susceptor has a thermal conductivity of at least 10 W / m / K.

[0019] In an exemplary embodiment, an article including an aerosolizable material is insertable at least partially into the heating zone through the outlet.

[0020] A third aspect of the present invention provides an aerosol delivery system comprising an aerosol delivery apparatus according to the first or second aspect of the present invention and an article comprising an aerosolizable material, the article being at least partially insertable within the heating zone such that first and second portions of the aerosolizable material are located at first and second positions within the heating zone, respectively.

[0021] In an exemplary embodiment, the article is at least partially insertable into the heating zone such that a third portion of the aerosolizable material is disposed at a third location within the heating zone.

[0022] In an exemplary embodiment, an article comprising an aerosolizable material is at least partially insertable into the heating zone through the outlet.

[0023] In an exemplary embodiment, each of the first and second portions of aerosolizable material is between 4 millimeters and 6 millimeters in length.

[0024] In an exemplary embodiment, the article is sized to protrude from the heating zone through the outlet during a heating session.

[0025] A fourth aspect of the present invention provides a method for heating an aerosolizable material during a heating session using an aerosol delivery device comprising: a heating zone for receiving at least a portion of an article comprising an aerosolizable material; an outlet through which, during use, an aerosol can be delivered from the heating zone to a user; and a heating device for causing heating of the article when the article is at least partially located within the heating zone, thereby generating an aerosol, wherein the heating device, when the article is at least partially located within the heating zone, heats a first portion of the aerosolizable material of the article to a temperature sufficient to aerosolize components of the first portion of the aerosolizable material without combusting a first portion of the aerosolizable material before or more quickly than heating a second portion of the aerosolizable material to a temperature sufficient to aerosolize components of the second portion of the aerosolizable material without combusting the first portion of the aerosolizable material, and wherein the second portion of the aerosolizable material is fluidly located between the first portion of the aerosolizable material and the outlet.

[0026] A fifth aspect of the present invention relates to a method of heating an aerosolizable material during a heating session using an aerosol delivery device comprising: a heating zone for receiving at least a portion of an article comprising an aerosolizable material; an outlet through which, in use, an aerosol can be delivered from the heating zone to a user; and a heating device for causing heating of the article when the article is at least partially located within the heating zone, thereby generating the aerosol, wherein the heating device comprises a first heating unit, a second heating unit, a third heating unit, and a controller, wherein, when the article is at least partially located within the heating zone, the first, second, and third heating units heat a first portion of the aerosolizable material on the article without burning the first portion of the aerosolizable material. the controller independently controls a first heating unit for heating a second portion of the aerosolizable material of the article to a temperature sufficient to aerosolize components of the second portion of the aerosolizable material, a second heating unit for heating a second portion of the aerosolizable material of the article to a temperature sufficient to aerosolize components of the second portion of the aerosolizable material, and a third heating unit for heating a third portion of the aerosolizable material of the article to a temperature sufficient to aerosolize components of the third portion of the aerosolizable material, wherein the second portion of the aerosolizable material is fluidly positioned between the first portion of the aerosolizable material and the outlet, and the third portion of the aerosolizable material is fluidly positioned between the second portion of the aerosolizable material and the outlet.

[0027] A sixth aspect of the present invention provides an aerosol delivery device configured to carry out the method of the fourth or fifth aspect of the present invention. [Brief explanation of the drawings]

[0028] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a schematic side view of an example aerosol delivery system. [Figure 2] FIG. 2 is a flow diagram illustrating an example method for heating an aerosolizable material. [Figure 3] FIG. 3 is a flow diagram illustrating another example of a method for heating an aerosolizable material. [Figure 4] FIG. 4 shows a schematic cross-sectional side view of the inductor configuration of the aerosol delivery device of the system of FIG. [Figure 5] FIG. 5 shows a schematic perspective view of an inductor of the inductor configuration of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0029] As used herein, the term "aerosolizable material" includes materials that provide volatile components upon heating, typically in the form of a vapor or aerosol. "Aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. "Aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. Aerosolizable material may be in the form of shredded tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, solid, amorphous solid, gelled sheet, powder, beads, granules, or aggregates, etc. "Aerosolizable material" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable material" may include one or more humectants, such as glycerol or propylene glycol.

[0030] In some examples, the aerosolizable material is in the form of an "amorphous solid." Any material referred to herein as an "amorphous solid" may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." In some cases, it may be referred to as a "thick film." In some examples, the amorphous solid may consist essentially of, or consist of, a gelling agent, an aerosol-generating agent, a tobacco material and / or a nicotine source, water, and optionally, a flavoring agent. In some examples, the gel or amorphous solid is in the form of a foam, such as an open-cell foam.

[0031] The susceptor is a material that can be heated by penetration of a varying magnetic field, such as an alternating magnetic field. The heating material can be an electrically conductive material, such that penetration by the varying magnetic field causes induction heating of the heating material. The heating material can be a magnetic material, such that penetration by the varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material can be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms.

[0032] Induction heating is the process of heating an electrically conductive object by penetrating it with a varying magnetic field. This process is described by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are properly positioned relative to each other, such that the varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated within the object, they flow against the object's electrical resistance, causing the object to heat. This process is called Joule heating, ohmic heating, or resistive heating.

[0033] In one example, the susceptor is in the form of a closed circuit. It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in greater or improved Joule heating.

[0034] Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by penetrating it with a changing magnetic field. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align with the field. Thus, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied changing magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0035] If an object is both conductive and magnetic, penetrating it with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can intensify Joule heating.

[0036] In each of the above processes, because heat is generated within the object itself rather than by an external heat source through thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting the appropriate object material and geometry, and by appropriate magnitude and orientation of the varying magnetic field relative to the object. Furthermore, because induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, greater design freedom and control over the heating profile can be achieved, and costs can be lower.

[0037] Referring to Figure 1, a schematic cross-sectional side view of an example aerosol delivery system is shown. System 1 includes an aerosol delivery device 100 and an article 10 comprising an aerosolizable material 11. Aerosolizable material 11 may be, for example, any of the types of aerosolizable materials discussed herein. In this example, aerosol delivery device 100 is a tobacco heating product (also known in the art as a tobacco heating device or a thermal non-combustion device).

[0038] In some examples, aerosolizable material 11 is a non-liquid material. In some examples, aerosolizable material 11 is a gel. In some examples, aerosolizable material 11 includes tobacco. However, in other examples, aerosolizable material 11 may consist of tobacco, consist substantially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, include aerosolizable materials other than tobacco, or be tobacco-free. In some examples, aerosolizable material 11 may include a vapor or aerosol-forming agent or humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol. In some examples, aerosolizable material 11 includes a reconstituted aerosolizable material, such as reconstituted tobacco.

[0039] In some examples, aerosolizable material 11 is substantially cylindrical with a substantially circular cross-section and longitudinal axis, while in other examples, aerosolizable material 11 may have a different cross-sectional shape and / or may not be elongated.

[0040] Aerosolizable material 11 of article 10 may have an axial length of, for example, 8 mm to 120 mm. For example, the axial length of aerosolizable material 11 may be greater than 9 mm, or 10 mm, or 15 mm, or 20 mm. For example, the axial length of aerosolizable material 11 may be less than 100 mm, or 75 mm, or 50 mm, or 40 mm.

[0041] In some examples, such as that shown in FIG. 1 , article 10 includes a filter arrangement 12 for filtering aerosol or vapor emitted from aerosolizable material 11 during use. Alternatively or additionally, filter arrangement 12 may be for controlling pressure drop across the entire length of article 10. Filter arrangement 12 may include one or more filters. Filter arrangement 12 may be of any type used in the tobacco industry. For example, the filter may be made of cellulose acetate. In some examples, filter arrangement 12 is substantially cylindrical with a substantially circular cross-section and longitudinal axis. In other examples, filter arrangement 12 may have a different cross-sectional shape and / or may not be elongated.

[0042] In some examples, filter arrangement 12 abuts a longitudinal end of aerosolizable material 11. In other examples, filter arrangement 12 may be spaced apart from aerosolizable material 11, such as by a gap and / or by one or more additional components of article 10. In some examples, filter arrangement 12 may comprise an additive or flavor source (such as an additive or flavor-containing capsule or thread), which may be held, for example, by a body of filtration material or between two bodies of filtration material.

[0043] The article 10 may also include a wrapper (not shown) wrapped around the aerosolizable material 11 and the filter configuration 12 to hold the filter configuration 12 against the aerosolizable material 11. The wrapper may be wrapped around the aerosolizable material 11 and the filter configuration 12 so that the free ends of the wrapper overlap each other. The wrapper may form part or all of the outer periphery of the article 10. The wrapper may be made of any suitable material, such as paper, card, or reconstituted aerosolizable material (e.g., reconstituted tobacco). The paper may be cigarette paper known in the art. The wrapper may also include an adhesive (not shown) that adheres the overlapping free ends of the wrapper to each other to help prevent the overlapping free ends from separating. In other examples, the adhesive may be omitted, or the wrapper may be different from that described. In other examples, the filter configuration 12 may be held against the aerosolizable material 11 by a connector other than the wrapper, such as an adhesive. In some examples, the filter configuration 12 may be omitted.

[0044] The aerosol delivery device 100 comprises a heating zone 110 for receiving at least a portion of the article 10, an outlet 120 through which, in use, an aerosol is deliverable from the heating zone 110 to a user, and a heating device 130 for causing heating of the article 10 when the article 10 is at least partially located within the heating zone 110, thereby generating an aerosol. In some examples, such as that shown in FIG. 1 , the aerosol is deliverable from the heating zone 110 to a user through the article 10 itself, rather than through any gap adjacent to the article 10. Nevertheless, in such examples, the aerosol still passes through the outlet 120 even while traveling within the article 10.

[0045] Apparatus 100 may define at least one air inlet (not shown) fluidly connecting heating zone 110 with the exterior of apparatus 100. A user may inhale the volatile components of the aerosolizable material by drawing the volatile component(s) from heating zone 110 through article 10. Once the volatile components are removed from heating zone 110 and article 10, air may be drawn into heating zone 110 through air inlet(s) of apparatus 100.

[0046] In this example, the heating zone 110 extends along line AA and is sized and shaped to accommodate only a portion of the article 10. In this example, the axis AA is the central axis of the heating zone 110. Further, in this example, the heating zone 110 is elongated, and thus the axis AA is the longitudinal axis AA of the heating zone 110. The article 10 is at least partially insertable into the heating zone 110 via the outlet 120 and protrudes from the heating zone 110 through the outlet 120 during use. In other examples, the heating zone 110 may be elongated or non-elongated and may be sized to receive the entire article 10. In some such examples, the device 100 may include a mouthpiece that may be positioned over the outlet 120 and through which the aerosol may be drawn from the heating zone 110 and the article 10.

[0047] In this example, when article 10 is at least partially located within heated zone 110, different portions 11a-11e of aerosolizable material 11 are located at different respective locations 110a-110e within heated zone 110. In this example, these locations 110a-110e are at different respective axial locations along axis AA of heated zone 110. Furthermore, in this example, because heated zone 110 is elongated, locations 110a-110e can be considered to be at different longitudinally spaced locations along the length of heated zone 110. In this example, article 10 can be considered to include five such portions 11a-11e of aerosolizable material 11 located at first location 110a, second location 110b, third location 110c, fourth location 110d, and fifth location 110e, respectively. More specifically, the second position 110b is fluidly located between the first position 110a and the outlet 120, the third position 110c is fluidly located between the second position 110b and the outlet 120, the fourth position 110d is fluidly located between the third position 110c and the outlet 120, and the fifth position is fluidly located between the fourth position 110d and the outlet 120.

[0048] The heating apparatus 130 includes a plurality of heating units 140a-140e, each capable of heating a respective one of the portions 11a-11e of the aerosolizable material 11 to a temperature sufficient to aerosolize its components when the article 10 is at least partially positioned within the heating zone 110. The plurality of heating units 140a-140e can be axially aligned with one another along the axis AA. Each of the portions 11a-11e of the aerosolizable material 11 thus heatable can have a length along the axis AA of 1 millimeter to 20 millimeters, e.g., 2 millimeters to 10 millimeters, 3 millimeters to 8 millimeters, or 4 millimeters to 6 millimeters.

[0049] The heating apparatus 130 in this example includes five heating units 140a-140e, namely, first heating unit 140a, second heating unit 140b, third heating unit 140c, fourth heating unit 140d, and fifth heating unit 140e. The heating units 140a-140e are at different axial positions along the axis AA of the heating zone 110. Furthermore, in this example, because the heating zone 110 is elongated, the heating units 140a-140e can be considered to be at different longitudinally spaced positions along the length of the heating zone 110. More specifically, second heating section 140b is located between first heating section 140a and outlet 120, third heating section 140c is located between second heating section 140b and outlet 120, fourth heating section 140d is located between third heating section 140c and outlet 120, and fifth heating section 140e is located between fourth heating section 140d and outlet 120. In other examples, heating device 130 can include more than five heating units 140a-140e, fewer than five heating units, for example, only four, only three, only two, or only one heating unit. The number of portion(s) of aerosolizable material 11 heatable by each heating unit(s) can vary accordingly.

[0050] The heating device 130 also includes a controller 135 configured to cause operation of the heating units 140a-140e to cause heating of the respective portions 11a-11e of the aerosolizable material 11 during use. In this example, the controller 135 is configured to operate the heating units 140a-140e independently of one another so that the respective portions 11a-11e of the aerosolizable material 11 can be independently heated. This may be desirable to provide gradual heating of the aerosolizable material 11 during use. Furthermore, in examples where the portions 11a-11e of the aerosolizable material 11 have different respective morphologies or properties, such as different tobacco blends and / or different application or inherent flavors, the ability to independently heat the portions 11a-11e of the aerosolizable material 11 can enable heating of selected portions 11a-11e of the aerosolizable material 11 at different times during a use session to generate aerosols having time-dependent predetermined properties. In some examples, the heating device 130 may nevertheless also be operable in one or more modes in which the controller 135 is configured to cause operation of two or more of the heating units 140a-140e simultaneously, such as all of the heating units 140a-140e, during a use session.

[0051] In this example, heating units 140a-140e comprise respective induction heating units configured to generate respective varying magnetic fields, such as alternating magnetic fields. Accordingly, heating apparatus 130 can be considered to comprise a magnetic field generator, and controller 135 can be considered to be a device operable to apply a variable current to inductors 150 of respective heating units 140a-140e. Additionally, in this example, apparatus 100 comprises susceptor 190 configured to be heatable by the penetration of the varying magnetic fields, thereby causing heating of heating zone 110 and articles 10 therein, during use. That is, portions of susceptor 190 are heatable by the penetration of the respective varying magnetic fields, thereby causing heating of respective portions 11a-11e of aerosolizable material 11 at respective locations 110a-110e within heating zone 110.

[0052] In some examples, the susceptor 190 is made of or includes aluminum. However, in other examples, the susceptor 190 may include one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some examples, the susceptor 190 may include a metal or a metal alloy. In some examples, the susceptor 190 may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze. In other examples, other materials may be used.

[0053] In some examples, such as those in which the susceptor 190 comprises steel (e.g., mild steel or stainless steel) or iron, such as aluminum, the susceptor 190 may include a coating to help prevent corrosion or oxidation of the susceptor 190 during use. Such coatings may include, for example, nickel plating, gold plating, or a ceramic or inert polymer coating.

[0054] In this example, the susceptor 190 is tubular and surrounds the heating zone 110. Indeed, in this example, the inner surface of the susceptor 190 partially defines the heating zone 110. The internal cross-sectional shape of the susceptor 190 may be circular or a different shape, such as elliptical, polygonal, or irregular. In other examples, the susceptor 190 may take a different form, such as a non-tubular structure that still partially surrounds the heating zone 110, or a protruding structure, such as a rod, pin, or blade, that penetrates the heating zone 110. In some examples, the susceptor 190 may be replaced by multiple susceptors, each of which is heatable by being penetrated by a respective one of the changing magnetic fields, thereby causing heating of a respective one of the portions 11a-11e of the aerosolizable material 1111. Each of the multiple susceptors may be, for example, tubular or may take one of the other forms described herein for the susceptor 190. In a further example, apparatus 100 may not include susceptor 190, and article 10 may include one or more susceptors that are heatable by the penetration of a varying magnetic field, thereby causing heating of respective portions 11a-11e of aerosolizable material 11. Each of one or more susceptors of article 10 may take any suitable form, such as a structure wrapped around or otherwise surrounding aerosolizable material 11 (e.g., a metal foil such as aluminum foil), a structure located within aerosolizable material 11, or a group of particles or other elements mixed with aerosolizable material 11. In examples where apparatus 100 does not include susceptor 190, susceptor 190 may be replaced by a heat-resistant tube that partially defines heating zone 110. Such a heat-resistant tube may be made of, for example, polyetheretherketone (PEEK) or a ceramic material.

[0055] In this example, the heating device 130 includes a power source (not shown) and a user interface (not shown) for user operation of the device. The power source in this example is a rechargeable battery. In other examples, the power source may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power source.

[0056] In this example, controller 135 is electrically connected between the power source and heating units 140a-140e. In this example, controller 135 is also electrically connected to the power source. More specifically, in this example, controller 135 is for controlling the supply of power from the power source to heating units 140a-140e. In this example, controller 135 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other examples, controller 135 may take different forms. Controller 135, in this example, is operated by user manipulation of a user interface. The user interface may include push buttons, toggle switches, dials, a touch screen, or the like. In other examples, the user interface may be remote and connected to the rest of aerosol delivery device 100 wirelessly, such as via Bluetooth®.

[0057] In this example, a user interacts with the user interface, causing the controller 135 to pass an alternating current through at least one inductor 150 of each of the heating units 140a-140e. This causes the inductor 150 to generate an alternating magnetic field. The inductor 150 and the susceptor 190 are appropriately positioned relative to one another so that the varying magnetic field generated by the inductor 150 penetrates the susceptor 190. If the susceptor 190 is conductive, this penetration generates one or more eddy currents within the susceptor 190. The eddy currents flow within the susceptor 190 against its electrical resistance, causing the susceptor 190 to heat due to Joule heating. If the susceptor 190 is magnetic, the orientation of the magnetic dipoles within the susceptor 190 changes with the applied magnetic field, thereby generating heat within the susceptor 190.

[0058] The apparatus 100 may include temperature sensors (not shown) for sensing the temperature of the heating chamber 110, the susceptor 190, or the article 10. The temperature sensors may be communicatively connected to the controller 135 so that the controller 135 can monitor the temperature of the heating chamber 110, the susceptor 190, or the article 10, respectively, based on information output by the temperature sensors. In another example, the temperature may be sensed and monitored by measuring an electrical characteristic of the system, for example, a change in the current in the heating units 140a-140e. Based on one or more signals received from the temperature sensors, the controller 135 may adjust the characteristics of the fluctuating or alternating current as needed to ensure that the temperature of the heating chamber 110, the susceptor 190, or the article 10, respectively, remains within a predetermined temperature range. The characteristics may be, for example, amplitude, frequency, or duty cycle. Within a predetermined temperature range, during use, the aerosolizable material 11 within the article 10 disposed within the heating chamber 110 is heated sufficiently to volatilize at least one component of the aerosolizable material 11 without burning the aerosolizable material 11. Thus, the controller 135 and the device 100 as a whole are configured to heat the aerosolizable material 11 to volatilize at least one component of the aerosolizable material 11 without burning the aerosolizable material 11. The temperature range may be from about 50°C to about 350°C, e.g., from about 100°C to about 300°C, or from about 150°C to about 280°C. In other examples, the temperature range may be other than one of these ranges. In some examples, the upper limit of the temperature range may be greater than 350°C. In some examples, the temperature sensor may be omitted.

[0059] Further discussion of the configuration of each of the heating units 140a-140e is provided below with reference to Figures 2 and 3. However, it should be noted at this stage that the size or extent of the varying magnetic field measured in the direction of axis AA is relatively small, and therefore the portion of the susceptor 190 that is penetrated by the varying magnetic field during use is correspondingly small. Accordingly, it may be desirable for the susceptor 190 to have a thermal conductivity sufficient to increase the proportion of the susceptor 190 that is heated by thermal conduction as a result of penetration by the varying magnetic field, so as to correspondingly increase the proportion of the aerosolizable material 11 that is heated by operation of each of the heating units 140a-140e. It has been found desirable to provide the susceptor 190 with a thermal conductivity of at least 10 W / m / K, optionally at least 50 W / m / K, and even optionally at least 100 W / m / K. In this example, susceptor 190 is made of aluminum and has a thermal conductivity of greater than 200 W / m / K, e.g., 200-250 W / m / K, e.g., about 205 W / m / K or 237 W / m / K. As noted above, each of portions 11a-11e of aerosolizable material 11 can have a length in the direction of axis AA of 1 millimeter to 20 millimeters, e.g., 2 millimeters to 10 millimeters, 3 millimeters to 8 millimeters, or 4 millimeters to 6 millimeters.

[0060] In this example, heating device 130 is configured to heat first portion 11 a of aerosolizable material 11 to a temperature sufficient to aerosolize components of first portion 11 a of aerosolizable material 11 before or more quickly than heating second portion 11 b of aerosolizable material 11 during a heating session. More specifically, controller 135 is configured to operate first and second heating units 140 a, 140 b to heat first portion 11 a of aerosolizable material 11 before or more quickly than heating second portion 11 b of aerosolizable material 11 during a heating session. Thus, during a heating session, the location at which thermal energy is applied to aerosolizable material 11 of article 10 is initially relatively fluidly spaced from outlet 120 and the user, and then moves toward outlet 120. This provides the advantage that the aerosol is generated from a continuous, "fresh" portion of the aerosolizable material 11 during the heating session, which can provide the user with a sensory-satisfying experience that may be more similar to that experienced when smoking a conventional combustible, factory-made cigarette.

[0061] Additionally, in some examples, the controller 135 is configured to cause the supply of power to the first heating unit 140a to cease for at least a portion (or all) of the time period during which the controller 135 is configured to cause operation of the second heating unit 140b. This provides the additional advantage that the aerosol generated in a given portion of the aerosolizable material 11 does not have to pass through another portion of the previously heated aerosolizable material 11, which could otherwise adversely affect the aerosol. For example, the aerosol passing through pre-heated or used aerosolizable material may result in an aerosol pickup component providing “off-notes” to the aerosol.

[0062] 1 , in some examples where heating device 130 has three or more heating units, heating device 130 may also be configured, during a heating session, to heat at least one further portion 11b-11e of aerosolizable material 11 to a temperature sufficient to aerosolize components of the further portion 11b-11e of aerosolizable material 11 before or more quickly than heating the further portion 11c-11e of aerosolizable material 11 that is fluidly closer to outlet 120. That is, controller 135 may be configured to appropriately operate the heating units to heat at least one further portion 11b-11e of aerosolizable material 11 before or more quickly than heating the further portion 11c-11e of aerosolizable material 11. For example, in the apparatus of FIG. 1 , heating device 130 may be configured to cause the following: heating the second portion 11b of the aerosolizable material 11 to a temperature sufficient to aerosolize the components of the second portion 11b of the aerosolizable material 11 before or more quickly than heating the third portion 11c of the aerosolizable material 11; heating the third portion 11c of the aerosolizable material 11 to a temperature sufficient to aerosolize the components of the third portion 11c of the aerosolizable material 11 prior to or more quickly than heating the fourth portion 11d of the aerosolizable material 11; Heating the fourth portion 11d of the aerosolizable material 11 to a temperature sufficient to aerosolize the components of the fourth portion 11d of the aerosolizable material 11 before or more quickly than heating the fifth portion 11e of the aerosolizable material 1111.

[0063] It will be appreciated that for a given duration of a heating session, the greater the number of heating units and associated portions of aerosolizable material 11, the greater the opportunity to generate aerosol from “fresh” or unused portions of aerosolizable material 11 extending along a given axial length. Alternatively, for a given duration of heating each portion of aerosolizable material 11, the greater the number of heating units and associated portions of aerosolizable material 11, the longer the heating session may be. It will be appreciated that the duration for which individual heating units may be activated may be adjusted (e.g., shortened) to adjust (e.g., reduce) the overall heating session, while at the same time, the power supplied to the heating elements may be adjusted (e.g., increased) to reach operating temperature more quickly. There may be a balance between the number of heating units (which may determine the number of “fresh puffs”), the overall session length, and the achievable power supply (which may be determined by the characteristics of the power source).

[0064] 2, a flow diagram illustrating an example of a method for heating an aerosolizable material during a heating session using an aerosol delivery device is shown. The aerosol delivery device used in method 200 includes a heating zone for receiving at least a portion of an article containing an aerosolizable material, an outlet through which an aerosol can be delivered from the heating zone to a user during use, and a heating device for causing heating of the article when the article is at least partially located within the heating zone, thereby generating an aerosol. The aerosol delivery device may be, for example, the one shown in FIG. 1 or any of the suitable variations thereof discussed herein.

[0065] The method 200 includes a heating device 130 heating 210 a first portion 11a of the aerosolizable material 11 of the article 10 to a temperature sufficient to aerosolize the components of the first portion 11a of the aerosolizable material 11 of the article 10 before or more quickly heating 220 a second portion 11b of the aerosolizable material 11 of the article 10 to a temperature sufficient to aerosolize the components of the second portion 11b of the aerosolizable material 11 when the article 10 is at least partially positioned within the heating zone 110, wherein the second portion 11b of the aerosolizable material 11 is fluidly positioned between the first portion 11a of the aerosolizable material 11 and the outlet 120.

[0066] It will be understood from the teachings herein that method 200 may be suitably adapted to include causing heating device 130 to also heat at least one further portion 11b-11e of aerosolizable material 11 to a temperature sufficient to aerosolize components of further portion 11b-11e of aerosolizable material 11, before or more quickly than heating further portion 11c-11e of aerosolizable material 11 that is fluidly closer to outlet 120, as described above.

[0067] Referring to Figure 3, a flow diagram illustrating another example of a method for heating an aerosolizable material during a heating session using an aerosol delivery device is shown. The aerosol delivery device used in method 300 includes a heating zone for receiving at least a portion of an article containing an aerosolizable material, an outlet through which an aerosol can be delivered from the heating zone to a user during use, and a heating device for causing heating of the article when the article is at least partially located within the heating zone, thereby generating an aerosol. The heating device includes a first heating unit, a second heating unit, a third heating unit, and a controller configured to operate the first, second, and third heating units. The aerosol delivery device may be, for example, the one shown in Figure 1 or any of the suitable variations thereof discussed herein.

[0068] The method 300 includes, when the article 10 is at least partially disposed within the heating zone 110, a first heating unit 140a heats 310 the components of the first portion 11a of the aerosolizable material 11 of the article 10 to a temperature sufficient to aerosolize the components of the second portion 11b of the aerosolizable material 11 of the article 10 (e.g., before or more quickly than the second portion 11b), and a second heating unit 140b heats 310 the components of the second portion 11b of the aerosolizable material 11 of the article 10 to a temperature sufficient to aerosolize the components of the second portion 11b of the aerosolizable material 11 of the article 10. The article 10 further includes a controller 135 that controls the first, second, and third heating units 140a, 140b, 140c independently of one another such that the first, second, and third heating units 140a, 140b, 140c heat 320 the third portion 11c of the aerosolizable material 11 of the article 10 to a temperature sufficient to aerosolize the components of the third portion 11c of the aerosolizable material 11 (e.g., before or more quickly than the third portion 11c), and the third heating unit 140c heats 330 the third portion 11c of the aerosolizable material 11 to a temperature sufficient to aerosolize the components of the third portion 11c of the aerosolizable material 11. The second portion 11b of the aerosolizable material 11 is fluidly located between the first portion 11a of the aerosolizable material 11 and the outlet 120, and the third portion 11c of the aerosolizable material 11 is fluidly located between the second portion 11b of the aerosolizable material 11 and the outlet 120.

[0069] It will be understood from the teachings herein that if the aerosol supply device used in method 300 is equipped with sufficient heating units, method 300 may be suitably adapted to include the heating device 130 also controlling the fourth and fifth heating units 140d, 140e independently of each other so that, when the item 10 is at least partially located within the heating zone 110, the fourth heating unit 140d heats the fourth portion 11d of the aerosolizable material 11 of the item 10 to a temperature sufficient to aerosolize the components of the fourth portion 11d of the aerosolizable material 11. The fifth heating unit 140e heats the fifth portion 11e of the aerosolizable material 11 of the item 10 to a temperature sufficient to aerosolize the components of the fifth portion 11e of the aerosolizable material 11, the fourth portion 11d of the aerosolizable material 11 being fluidly positioned between the third portion 11c of the aerosolizable material 11 and the outlet 120, and the fifth portion 11e of the aerosolizable material 11 being fluidly positioned between the fourth portion 11d of the aerosolizable material 11 and the outlet 120.

[0070] One of the heating units 140a-140e of the heating device 130 will now be described in more detail with reference to Figures 4 and 5, which respectively show a schematic cross-sectional side view of an inductor arrangement 150 of the heating unit and a schematic perspective view of an inductor 160 of the inductor arrangement 150.

[0071] Inductor configuration 150 includes an electrically insulating support 172 and an inductor 160. Support 172 has opposing first and second sides 172a, 172b, and portions 162, 164 of inductor 160 are on first and second sides 172a, 172b of support 172, respectively.

[0072] More specifically, the inductor 160 includes a conductive element 160. The element 160 includes a conductive, non-helical first portion 162 that coincides with a first plane P1 and a conductive, non-helical second portion 164 that coincides with a second plane P2 spaced apart from the first plane P1. In this example, the second plane P2 is parallel to the first plane P1, but this need not be the case in other examples. For example, the second plane P2 may be at an angle relative to the first plane P1, such as an angle of 20 degrees or less, 10 degrees or less, or 5 degrees or less. The inductor 160 also includes a first conductive connector 163 that electrically connects the first portion 162 to the second portion 164. The first portion 162 is on a first side 172a of the support 172, and the second portion 164 is on a second side 172b of the support 172. The conductive connector 163 penetrates the support 172 from the first side surface 172a to the second side surface 172b. The conductive connection part 163 may have a structure in which the surface of a through hole provided in the support 172 is plated (for example, copper plated).

[0073] The support 172 can be made of any suitable electrically insulating material. In some examples, the support 172 includes a matrix (such as an epoxy resin, optionally with a filler such as a ceramic) and a reinforcing structure (such as a woven or nonwoven material, such as fiberglass or paper).

[0074] Inductor 160 may be made from any suitable conductive material(s). In some examples, inductor 160 is made from copper.

[0075] In some examples, inductor configuration 150 includes or is formed from a PCB. In such examples, support 172 is a non-conductive substrate of the PCB, which may be formed from a material such as FR-4 glass epoxy or cotton paper impregnated with phenolic resin, and first portion 162 and second portion 164 of inductor 160 are tracks on the substrate. This facilitates manufacturing of inductor configuration 150 and also allows portions 162, 164 of element 160 to be thin and closely spaced, as described in more detail below.

[0076] In this example, the first portion 162 is a first partial annular body 162, and the second portion 164 is a second partial annular body 164. Furthermore, in this example, the first and second portions 162, 164 each follow only a portion of a respective circular path. Thus, the first portion or first partial annular body 162 is a first arc of a circle, and the second portion or second partial annular body 164 is a second arc of a circle. In other examples, the first portion 162 and the second portion 164 may follow a path other than a circle, such as an ellipse, a polygon, or an irregular shape. However, matching the shape of the first portion 162 and the second portion 164 to the shape (or at least an aspect of the shape, such as the perimeter) of the respective adjacent portion of the susceptor 190 (whether provided in the apparatus 100 or the article 10) helps to provide improved and more consistent magnetic coupling between the inductor 160 and the susceptor 190. Furthermore, in examples where the first portion 162 and the second portion 164 are each arcs, providing the radii of the arcs are equal, this can also help to result in more consistent magnetic field generation along the length of the inductor 160, and therefore more consistent heating of the susceptor 190.

[0077] The inductor arrangement 150 has a through-hole 152 that is radially inward of and coaxial with the first and second portions 162, 164 or partial annulus. In the assembled apparatus 100, the susceptor 190 and heating zone 110 extend through the through-hole 152, such that the portions 162, 164 of the element 160 together at least partially surround the susceptor 190 and heating zone 110. In examples where the susceptor 190 is replaced by multiple susceptors, each of the multiple susceptors can be positioned to extend through the through-hole 152 of one or more inductor arrangements 150 of a respective heating unit 140a-140e. In some examples, the or each susceptor does not extend through the through-hole 152, but rather is adjacent (e.g., axially) to the associated element 160.

[0078] As mentioned above, in examples where the heating apparatus 130 does not include a susceptor, the heating zone 110 may still extend through some or all of the through-holes 152 of the inductor configuration 150 of each heating unit 140a-140e. In some such examples, the article 10 includes one or more susceptors, such as metal foil (e.g., aluminum foil) wrapped around or otherwise surrounding the aerosolizable material 11, and / or a susceptor, such as in the form of a pad, at one end of the article 10 axially adjacent to the aerosolizable material 11 of the article 10. In some examples, the susceptor of an article 10 including a liquid or gel or other flowable aerosolizable material may include a (e.g., metallic) susceptor coated in or on a (e.g., ceramic) core. In some examples, the portions 11a-11e of the aerosolizable material 11 have the same respective shapes or characteristics, or different respective shapes or characteristics, for example, different tobacco blends and / or different applied or inherent flavors. In some such examples, the article 10 may include multiple susceptors, each of which is positioned and heatable to heat a respective one of the portions 11a-11e of the aerosolizable material 11. In some examples, the portions 11a-11e of the aerosolizable material 11 are isolated from one another. In other examples, there may be multiple heating zones, each of which is located between a pair of inductor configurations 150. Some or all of the multiple heating zones may not pass through the through-holes 152. The multiple heating zones may be intended to receive respective articles 10 containing aerosolizable material 11. The aerosolizable material 11 of each article 10 may have the same or different respective shapes or properties. In some examples, the through-holes 152 may be omitted.

[0079] As can be best understood from further consideration of Figure 5, when viewed in a direction orthogonal to first plane P1, and therefore in the direction of axis BB of inductor 160, first and second portions 162, 164 extend in opposite rotational directions from first conductive connector 163. For example, when viewing inductor 160 of Figure 5 from left to right in the direction of axis BB as depicted in Figure 5, first portion 162 of inductor 160 extends in a counterclockwise direction from connector 163, and second portion 164 of inductor 160 extends in a clockwise direction from connector 163.

[0080] Furthermore, in this example, when viewed in a direction perpendicular to the first plane P1, the first portion 162 or first partial annular body partially overlaps the second portion 164 or second partial annular body. In this example, the first portion 162 and the second portion 164 together define approximately 1.75 turns about line BB, which is perpendicular to the first plane P1 and the second plane P2. In other examples, the number of turns may be at least 0.9, such as another number other than 1.75. For example, the number of turns may be between 0.9 and 1.5, or between 1 and 1.25. In other examples, the number of turns may be less than 0.9, but reducing the number of turns per support 172 may result in an increase in the axial length of the inductor assembly 150.

[0081] Furthermore, when viewed orthogonal to the first plane P1, the first portion 162 or first partial annular body, as well as the second portion 164 or second partial annular body, at least partially overlap the first conductive connector 163. This is facilitated by the inductor configuration 150 comprising or formed from a PCB (or more generally, a planar substrate layer). Notably, in such examples, the first conductive connector 163 takes the form of a “via” extending through the support 172. Even in examples where the inductor configuration 150 is not formed from a PCB, the connector 163 may still extend through the support 172. This overlapping arrangement allows the inductor 160 to occupy a relatively small footprint when viewed orthogonal to the first plane P1, compared to a comparative example in which the first and second portions 162, 164 are connected by the connector 163 spaced radially outward from the first and second portions 162, 164. Furthermore, this overlapping arrangement allows for an increased width of the through hole 152, as compared to a comparative example in which the first and second portions 162, 164 are connected by a connector 163 spaced radially inward of the first and second portions 162, 164. Nevertheless, in some examples, the connector 163 may be radially inward or radially outward of the first and second portions 162, 164. This may be achieved with the connector 163 formed by a "through via" extending through the support 172. Through vias tend to be less expensive to form than blind vias because they can be formed after the PCB is manufactured.

[0082] Note that in this example, inductor configuration 150 includes two additional supports 174, 176, and element 160 includes two additional conductive non-helical portions 166, 168 that coincide with two respective spaced-apart planes P3, P4 that are parallel to first plane P1. In other examples, one or each of spaced-apart planes P3, P4 may be at an angle relative to first plane P1 of 20 degrees or less, or 10 degrees or less, or 5 degrees or less, etc. Second and third conductive non-helical portions 164, 166 are on opposite sides of second support 174 and are electrically connected by second conductive connector 165. Third and fourth conductive non-helical portions 166, 168 are on opposite sides of third support 176 and are electrically connected by third conductive connector 167. Second and third conductive connectors 165, 167 are rotationally offset from first conductive connector 163. In configurations where supports 172, 174, and 176 are formed as PCBs, connectors 163 and 167 may be formed as "blind vias" and connector 165 may be formed as a "buried via."

[0083] In this example, the first, second, third, and fourth portions or partial annular bodies 162, 164, 166, 168 together define a total of approximately 3.6 turns about a longitudinal axis BB that is perpendicular to the first and second planes P1, P36. In other examples, the total number of turns may be other than 3.6, such as another number between 1 and 10. For example, the total number of turns may be between 1 and 8, or between 1 and 4. Having a relatively low total number of turns is believed to increase the voltage available to the susceptor 190 (whether provided in the apparatus 100 or the article 10) for forcing current to flow along or around the susceptor 190.

[0084] It should be noted that the inductor 160 also comprises first and second terminals 161, 169 across the inductor 160 for passing current through the inductor 160 in use.

[0085] In this example, each of the first, second, and third supports 172, 174, and 176 has a thickness of approximately 0.85 millimeters. In some examples, one or more of the supports 172, 174, and 176 may have a thickness other than 0.85 millimeters, such as a thickness ranging from 0.2 millimeters to 2 millimeters. For example, each of the thicknesses may be between 0.5 millimeters and 1 millimeter, or between 0.75 millimeters and 0.95 millimeters. In some examples, the thicknesses of the respective supports 172, 174, and 176 are equal to or substantially equal to one another. In other examples, one or more of the supports 172, 174, and 176 may have a thickness that is different from the thickness of one or more of the other supports 172, 174, and 176.

[0086] In this example, each of the portions 162, 164, 166, and 168 of the inductor 160 has a thickness of approximately 142 micrometers measured in a direction perpendicular to the first plane P1. In some examples, one or more of the portions 162, 164, 166, and 168 of the inductor 160 may have a thickness other than 142 micrometers, such as another thickness in the range of 10 micrometers to 200 micrometers. For example, each of the thicknesses may be between 25 micrometers and 175 micrometers, or between 100 micrometers and 150 micrometers.

[0087] In an example where the inductor configuration 150 is fabricated from a PCB, the thickness of the material of the inductor 160 can be determined by “plating” the material onto the substrate prior to construction of the PCB. Some standard circuit boards have a 1 oz layer of conductive material, such as copper, on the substrate. A 1 oz layer has a thickness of approximately 38 micrometers. Plating up to a 4 oz layer increases the thickness to approximately 142 micrometers. Increasing the thickness makes the structure of the inductor configuration more robust and reduces system losses due to a corresponding reduction in ohmic losses. Increasing the volume of the material of the inductor 160 increases the thermal capacity of the inductor 160, reducing the temperature gain for a given heat input. This can be beneficial because it can be used to help ensure that the temperature of the inductor 160 itself during use does not become so high as to cause damage to the structure of the inductor configuration 150. In some examples, the thicknesses of the respective portions 162, 164, 166, and 168 of the inductor 160 are equal to or substantially equal to each other. This can result in a more consistent heating effect generated by the different portions of the inductor 160. In other examples, one or more of the portions 162, 164, 166, 168 of the inductor 160 may have a thickness that is different from the thickness of one or more of the other portions 162, 164, 166, 168 of the inductor 160. This may be intentional, in some examples, to provide an increased heating effect produced by a particular portion of the inductor 160 compared to the heating effect produced by other portions of the inductor 160.

[0088] In this example, each of the planes P1 to P4 is a plane or substantially a plane, but in other examples this need not be the case.

[0089] 5, the first and second planes P1 and P2 are spaced apart by a distance D1 in the B-axis direction of the inductor 160. In this example, the distance D1 between the first and second planes P1 and P2 measured in a direction perpendicular to the first and second planes P1 and P2 is less than 2 millimeters, for example, less than 1 millimeter. In other examples, the distance D1 may be, for example, between 1 millimeter and 2 millimeters, or more than 2 millimeters.

[0090] The combination of the first conductive connector 163 and the first and second portions 162, 164 of the conductive element 160 can be considered to be or approximate a helical coil. Indeed, the complete inductor 160 can be considered to be or approximate a helical coil.

[0091] Given the distances D1, D2, and D3 between adjacent pairs of planes P1, P2, P3, and P4, the coil in this example can be considered to have a pitch of less than 2 millimeters, e.g., less than 1 millimeter. In other examples, the pitch may be, for example, between 1 millimeter and 2 millimeters, or greater than 2 millimeters. Optionally, the distance between each adjacent pair of portions 162, 164, 166, and 168 of element 160 is equal to or differs by less than 10% from the distance between adjacent pairs of portions 162, 164, 166, and 168 of element 160. This can result in more consistent magnetic field generation along the length of inductor 160 and, therefore, more consistent heating of susceptor 190.

[0092] The smaller the pitch, the greater the ratio of magnetic field strength to the mass of the susceptor 190 (whether located in the apparatus 100 or the article 10) to which energy is being applied. However, this must be balanced against the adverse effects of the "proximity effect." In particular, the smaller the pitch, the greater the losses due to the proximity effect. Therefore, careful pitch selection is required to reduce losses in the inductor 160 while increasing the energy available to heat the susceptor 190. In some examples, when the inductor 160 and controller 135 are properly configured, they have been found to cause the generation of a magnetic field having a magnetic flux density of at least 0.01 Tesla. In some examples, the magnetic flux density is at least 0.1 Tesla.

[0093] Fabricating inductor structure 150 from a PCB allows for a relatively small pitch. Given the present teachings, one skilled in the art could conceive of other methods of fabricating an inductor coil with a similarly small pitch. However, fabricating inductor structure 150 from a PCB is also likely to be cheaper than some other methods of fabricating an inductor coil, such as by winding Litz wire.

[0094] While the example inductor configuration 150 shown in the figures has three supports 172, 174, 176 and an inductor 160 with four portions 162, 164, 166, 168, this need not be the case in other examples. In some examples, the inductor 160 may have more or fewer portions than four, such as only three portions 162, 164, 166 or only two portions 162, 164. In some examples, the inductor configuration 150 may have more or fewer supports than three, such as only two supports 172, 174 or only one support 172. Indeed, in some examples, the number of supports in the inductor configuration 150 may be only one, and the number of portions of the inductor 160 may be only two, with the two portions 162, 164 of the inductor 160 on either side of a single support 172. It will be appreciated that the number of conductive connectors 163, 165, 167 must be correspondingly adjusted depending on the number of two sections 162, 164, 166, 168 present in inductor 160. In some instances, inductor 160 may be provided without any supports between sections 162, 164, 166, 168 of inductor 160. In such instances, it is desirable for inductor 160 to be strong enough to be self-supporting.

[0095] The inductor configuration 150 or its inductor 160 of each heating unit 140a-140e can be provided in an inductor assembly or magnetic field generator 130 for inclusion in an aerosol delivery device, such as the device 100 of FIG. 1 or any of its variations described herein. The inductors 160 of the inductor assembly, magnetic field generator 130, or device 100 can be spaced apart by a distance selected to allow for heating of a majority or other desired amount of the aerosolizable material 11 while avoiding or reducing interference between the inductors 160. As discussed herein, a relatively small pitch of the inductors has been found to result in the generation of a relatively focused, varying magnetic field, such that other ones of the inductors 160 can be placed relatively close together without significant interference. Adjacent inductors 160 may be spaced apart by a distance of 5 to 50 millimeters, e.g., 10 to 40 millimeters, or 15 to 30 millimeters. In other examples, other distances can be used.

[0096] In some examples, heating units 140a-140e are heating units other than respective induction heating units, such as respective resistance heating units. In some such examples, aerosol delivery apparatus 100 may be configured to perform one or both of methods 200, 300 for heating aerosolizable material described above, or any of the suitable variations thereof described herein. In some such examples, aerosol delivery apparatus 100 and / or article 10 may include at least one thermally conductive element having a thermal conductivity sufficient to increase the proportion of the thermally conductive element that is heated by thermal conduction as a result of heating by heating units 140a-140e, so as to correspondingly increase the proportion of aerosolizable material 11 that is heated by operation of each of heating units 140a-140e. The or each thermally conductive element may take the form of any of the suitable susceptors discussed herein, such as, for example, a metal (e.g., aluminum) foil in article 10 or a metal (e.g., aluminum) tubular component in apparatus 100.

[0097] Once all, substantially all, or many of the volatilizable components of the aerosolizable material 11 in the item 10 have been consumed, the user can remove the item 10 from the heating chamber 110 of the device 100 and discard the item 10.

[0098] In some examples, article 10 is sold, supplied, or otherwise provided separately from device 100 with which article 10 can be used. However, in some examples, device 100 and one or more of articles 10 may be provided together as a system, such as a kit or assembly, possibly with additional components such as cleaning implements.

[0099] To address various problems and advance the art, the entire present disclosure provides by way of illustration and example various embodiments by which the claimed inventions may be practiced and which provide improved aerosol delivery devices, improved aerosol delivery systems, and improved methods for heating aerosolizable materials. The advantages and features of the present disclosure are merely representative examples of embodiments and are not exhaustive or exclusive. They are presented solely to aid in the understanding and teaching of the claimed and otherwise disclosed features. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limitations on the present disclosure as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. an aerosol delivery device positioned to receive a first portion of aerosolizable material located at a first location and a second portion of aerosolizable material located at a second location, a first heating unit configured to heat the first portion of the aerosolizable material to a temperature sufficient to aerosolize the components thereof; a second heating unit configured to heat the second portion of the aerosolizable material to a temperature sufficient to aerosolize the components thereof; an outlet through which the aerosol can be delivered to a user in use; an air inlet; the first position and the second position are at different positions spaced apart in a longitudinal direction; the second location is fluidly located between the first location and the outlet; the first and second heating units are resistive heating units; The aerosol delivery device, wherein the second portion of the aerosolizable material is a portion of a solid aerosolizable material.

2. 10. The aerosol delivery device of claim 1, wherein the first and second heating units are at different longitudinally spaced locations.

3. Further comprising a controller, 3. The aerosol delivery device of claim 1, wherein the controller is configured to operate the first and second heating units to heat respective portions of the aerosolizable material independently of each other.

4. 3. The aerosol delivery device of claim 1, wherein the first and second portions of aerosolizable material have different morphologies.

5. 3. The aerosol delivery device of claim 1, wherein the first and second portions of aerosolizable material have different properties.

6. Further comprising a controller, 3. The aerosol delivery device of claim 1, wherein the controller is configured to cause operation of the first and second heating units simultaneously during a use session.

7. 3. The aerosol delivery device of claim 1, further comprising a mouthpiece positionable over the outlet and through which the aerosol can be drawn.

8. 10. The aerosol delivery device of claim 1, wherein the second heating unit is located between the first heating unit and the outlet.

9. A method for producing an aerosolizable material comprising: a second portion of the aerosolizable material located at a second location; and a first heating unit configured to heat the first portion of the aerosolizable material to a temperature sufficient to aerosolize the components thereof; a second heating unit configured to heat the second portion of the aerosolizable material to a temperature sufficient to aerosolize the components thereof; an outlet through which the aerosol can be delivered to a user in use; an air inlet; the first position and the second position are at different positions spaced apart in a longitudinal direction; the second location is fluidly located between the first location and the outlet; the first and second heating units are resistive heating units; The aerosol delivery system, wherein the second portion of the aerosolizable material is a portion of a solid aerosolizable material.

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